Fuel Gauge Sender: Service and Repair

NOTE: The following procedure describes removing the complete fuel delivery unit with Fuel Level Sender Unit. When servicing level sender unit only some steps may not apply.

Special tools, testers and auxiliary items:
- 3217 Ring nut spanner
- 3307 Fuel pump wrench
- VAG 1332 Torque wrench 40 to 200 Nm (30 to 148 ft lb)

Removing:
- Note "Safety precautions" at Fuel Delivery and Air Induction/Service Precautions before starting work.

CAUTION! Obtain radio anti-theft code before disconnecting Battery Ground.

- With ignition switched OFF disconnect battery Ground cable.
- Remove floor cover.





- Disconnect 4-pin harness connector, supply and return lines -arrows- from flange.

WARNING! Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.





- Remove union nut with 3217 spanner.
- Pull flange and seal out of the opening in fuel tank.
- Pull off fuel lines and connector on lower side of flange.
- Unclip fuel sender (G) on back pressure housing and remove.





- Turn fuel delivery unit approx. 15° anti-clockwise onto stop using 3307 wrench and remove.

NOTE: If the delivery unit is replaced; carefully and thoroughly drain the old delivery unit before disposing of it.

Installing:

NOTES:
- Installing the fuel delivery unit is carried out in the reverse order of the removal procedure.
- Do not bend the fuel gauge sending unit arm when installing.
- Coat flange seal with fuel when fitting.
- Ensure fuel hoses are seated securely.
- Do not interchange supply and return hoses (return hose -blue-).
- Secure fuel hoses with spring clamps.





- Note Installation position of fuel delivery unit flange:
Mark on flange -1- must align with fuel tank mark -2-.
- After installing fuel delivery unit flange, check that the supply return and breather lines are still clipped onto the fuel tank.